Betacontrol Indicon One Online Thickness Gauge

Overview

The Betacontrol Indicon One Online Thickness Gauge is an industrial-grade, non-contact thickness measurement system engineered for real-time, continuous monitoring of material thickness across high-speed manufacturing lines. Based on modular sensor architecture, the Indicon One platform supports multiple physical measurement principles—including beta-ray transmission and backscatter, infrared absorption, ultrasonic time-of-flight, laser triangulation, X-ray attenuation, microwave dielectric response, and white-light interferometry—enabling precise adaptation to diverse material properties and production constraints. Unlike laboratory-based gauges, the Indicon One is designed for permanent installation in harsh industrial environments, delivering stable, drift-compensated measurements under varying temperature, humidity, and mechanical vibration conditions. Its core function is to provide traceable, repeatable thickness data at line speeds up to 500 m/min, supporting closed-loop feedback to extrusion, calendering, coating, and laminating control systems. The system meets foundational metrological requirements for in-process quality assurance, aligning with ISO 5725 (accuracy and precision of measurement methods) and supporting compliance-driven documentation workflows.

Key Features

• Modular sensor selection: Choose from seven physically distinct sensing modalities—beta-ray, IR, ultrasonic, laser, X-ray, microwave, or white-light interferometry—based on material composition, opacity, surface roughness, and required resolution.
• Real-time thickness output: Analog (4–20 mA, 0–10 V) and digital (EtherCAT, PROFINET, Modbus TCP) interfaces enable seamless integration with PLCs, DCS, and MES platforms.
• Automatic calibration verification: Built-in reference standards and drift compensation algorithms ensure long-term stability without manual recalibration intervals exceeding 6 months under normal operation.
• Ruggedized industrial housing: IP65-rated enclosure with optional cooling jackets and anti-condensation heaters for deployment in extrusion hoods, coating ovens, or ambient-uncontrolled roll-to-roll environments.
• Multi-layer capability: Configurable for simultaneous measurement of substrate thickness and coating layer thickness (e.g., polymer film + adhesive + metallization) where sensor physics permit.
• Edge detection & profile mapping: Integrated scanning mode generates full-width thickness profiles (up to 2,048 points per scan) with sub-millimeter spatial resolution for defect localization and uniformity analysis.

Sample Compatibility & Compliance

The Indicon One accommodates a broad spectrum of flexible and rigid substrates, including polyolefin and PET films (cast, blown, biaxially oriented), aluminum and copper foils, nonwoven webs, paper and cardboard grades, rubber-coated textiles, PVC flooring, PU foams, and electroplated steel strips. Sensor selection is determined by material density, atomic number, water content, and surface reflectivity—for example, beta-ray transmission is preferred for low-Z polymers (<100 µm), while X-ray is applied for high-density metals or multi-layer composites. All configurations comply with EU Machinery Directive 2006/42/EC and electromagnetic compatibility (EMC) Directive 2014/30/EU. Radiation-based variants (beta-ray, X-ray) include certified shielding and interlock circuitry meeting IEC 61000-6-4 and national regulatory requirements for industrial radiation devices.

Software & Data Management

The Indicon One operates with Betacontrol’s proprietary IndiSoft Suite—a Windows-based configuration, visualization, and diagnostics platform supporting both local HMI and remote web access via secure HTTPS. Software features include real-time trend plotting, statistical process control (SPC) charting (X̄-R, Cpk), alarm logging with timestamped event capture, and export of raw scan data in CSV and HDF5 formats. Audit trails record all parameter changes, user logins, and calibration events in accordance with FDA 21 CFR Part 11 readiness (electronic signatures and data integrity controls available upon configuration). Data synchronization with enterprise SQL databases and cloud-based historian systems (e.g., OSIsoft PI, Ignition) is supported through OPC UA connectivity.

Applications

• Plastics: Thickness profiling of cast PP films, BOPP lines, and TPU elastomer sheets during chill roll quenching.
• Paper & board: Basis weight and caliper control in multi-ply corrugated medium and linerboard production.
• Coatings: Quantitative verification of acrylic, PVDF, or ceramic coatings on aluminum composite panels prior to curing.
• Tires & rubber: Rubber compound thickness on textile or steel cord carcass plies in bias and radial tire building.
• Electronics: Copper foil thickness verification on flexible printed circuit (FPC) base materials pre-lamination.
• Automotive: Foam density mapping in headliner substrates and acoustic insulation layers using microwave dielectric response.

FAQ

Which sensor technology is recommended for measuring opaque polymer films less than 50 µm thick?
Beta-ray transmission is typically selected for thin, low-density polymer films due to its high signal-to-noise ratio and insensitivity to surface gloss or color.
Can the Indicon One interface directly with Siemens S7-1500 PLCs?
Yes—PROFINET and Modbus TCP protocols are natively supported; EtherCAT requires optional gateway configuration.
Is radiation safety certification included with beta-ray equipped units?
Each beta-ray system ships with type-approved shielding, operational interlocks, and documentation compliant with national radiation protection authorities (e.g., BfS in Germany, NRC in the US).
What is the minimum measurable thickness for laser-based configuration on smooth metallic foils?
Laser triangulation achieves ±0.1 µm repeatability on polished aluminum or stainless steel foils down to 10 µm nominal thickness.
Does the system support automatic compensation for temperature-induced thermal expansion of the measured web?
Yes—integrated temperature input channels allow real-time correction using user-defined CTE coefficients per material grade.